Method of making artificially-integrated shaped bodies and the product of said method



oct. 27,1925.

P. A. ANDREWS METHOD 0F KAKINGHARTIFICIALLY INTEGRATED SHAPED BODIES AND THE PRODUCT 0F SAID METHOD Filed lay 7 1924 frz/Venier hill/Jp undjew s @Mh-4h.

is Jfyg l tion-b 'the heat produce '1 his invention 40 provi es such materials and articles made relatively non -fictile and dr uni-TED sTArEsr-ATENT oFFicE.

PHILIP n. ANDREWS, or wAUxneAN, ILLINoIs, Assmann' To JoHNsLnANvILm- INC., OF NEW YORK, N. Y., A

CORPORATION Ol' NEW YORK.

mrrnon or AMmmm an'rIFIcIALLY-mzrnenn'rnn fsHArnD DoDIEs ANDrIIE PRODUCT.

or SAID lppiiauon ma ,hay 7,

To all whom, it may concern.'

Be it' known that I," PHILIP A. ANDREWS, acitizen of the United States of America, and resident of Waukegan, in the county7 of .Lake and State of Illinois, have invent-- ed new and useful Improvements in Meth-` ods of Making ArtificiallyIntegrated Sha ed Bodies and the Products of Said Met ods, of which the following is a specication.

This invention relates to` artificiallyintegrated shaped bodies of tough and/ relatively. infrangible pressure-and frictionresistantmaterials (suitable for brake and l5 clutch linings or acings and other urposes); and to the art or method of ma lug such bodies. .One ob'ect isto provide an improved Wa-y of ma ing a dense, shaped .body of high mechanical resistance, .capable of withstanding high temperatures without disintegration, and capab e of reduction by wear without alterationof its Vqualification for the indicated uses.`

Materials and articles of the kind referred to are required to be resistant to the severe breakin strains, pressure, friction, attrition and iigh temperatures incidental to use as the contact shoe or surface of thc brake-block or clutch lining or the like for which they are principally in Ldemand, and it isessential that the mechanical structure produced shall be sufficiently tough, in` frangible and solid to resist the stresses and strains of such uses without deformation; sutliciently uniform in structure to continuously present the same character of suitable `new .surfaces when worn down; and suliciently heat resistant to reventdeteriora- .l of them, and a method or art of producing the materials and articles. f

The method recommended ncomprises assembl and mixture of suitable heat-resistant li rous materials, Such as asbestos fiber, crude or refined, with a cementitious binder in"a relatively dry, bibulous or'anhydrous s tatef'and capableof solidification or set- .ting upon treatment with water orother freagent; securing homogeneity and absence of gross' voids by molding the mass in. this` state to the desired shape 1 with the aid o suitable. pressure; subjecting the molded result to the mn'rHoD.

A 1924. semina. 711,631. }7

action of a cement-setting reagent in such` 55.. a way as .toretain the molded orm;dry mg, and impregnating the product with 'a .Huid capable of subsequent uniformsolidification.

The specific application of vthe method 00 may be modified in commercial adaptation to accord with the particular uses, the ma terials and facilities available, in order to. provide a variety'of finished products havmg various properties depending .upon their particular intended uses; representative procedures will now be described, as related tothe manufacture of brake blocks, for examples only ofthe procedure 'and products according to the invention. i

In the accompanying drawings,

Fig. 1 is a erspective of a molded block according tot e invention; Fig. 2 is a transverse section of a metal brake shoe showing a` block according to the invention formed in'place; and

Fig. 3 is a perspective of a block illus.- trat-ingI a typical instance of a product liccording to the invention.

In the drawings, the segmental block 1 3 may have a molded, ground or machined cylindrical face 2 and side surfaces 3 and 4 formed by molding; or by molding an annulus or a larger segment of an annulus and sawing into the form shown. Preferably the molded form corres nds in dimensions closely to the `finis ed product' illustrated, grinding or' machinin operations being relied upon for 'a finis ed sur- `face only, as distinguished from anyeneces- '90 sity..to make to shape by cutting from a larger mass.

undercut cavity of a metal brake-shoe 6 of M any desired form.

Blocks of the kind typified by the block 8 of-Fig`.3 may be molded to provide the channels 9 'and the remaining surfaces, or

have its cylindrical working-face 10 only 100v ground or machined.

Whatever. the particular form of block, collar., disk', annu us. or s ment of-a geo-I metrieal solid desired for e intended use, this invention provides a method of producing the formed object or piece -out of amaterial highly satisfactory 1n respect to frictiona'l eiet, great strength, great du- 106. COMPoslTioNs,

COMING R PLAsuC tures of these being typical rability, and resistance to destructive change by heat; and also provides a way of producing the product.in a form requiring a minimum of grinding, machining or finishing.A

As a base material, asbestos fibre, crude or refined, maybe employed, but ordinarily asbestoslfibre wastes, waste asbestos yarn, or picker stock from asbestos felts or woven fabrics, are entirely satisfactory for the purpose, short fibre asbestos, scrap asbestos yarn, and waste from weaving asbestos-covered metal-core yarns, or mix- A suitable ma-` terial.

This, or other suitable material, prepared by cardingor opening operations, is integrated into a compact mass of the desired qualities by mixing and molding it together with components of a cementitious binder,

p causing the cementing reaction to take .place while the material retains a compressed molded form; driving off any excess of uncombined liquid in the`integrated b lock; and impregnating with a suitable solidifiable interpenetrating imiregnant serving to fill the voids, to inhibit urther chemical reactions, and usefull 'to modify the lfrictional effect of any sur ace ofthe impregnated cementintegrated fibrous mass.

As a ste to this end, the incomplete components o the cement element in a bibulous or anhydrous and comminuted. state, free from lumps and read to react into a solid upon contact with t e reagent, are thoroughly mixed with the fibrqusconstituents such as asbestos, (and the desirable mclu'sions, if any, such as lengths of .fine wire), to constitute a non-fictile mass; this is rendered capable of primary cohesion under great pressures by a liquid addition (prefverably of the cement-settin .reagent such as water) in quantities less t ian sufficient to. complete reaction, and less than sufficient to promote fluidity of the mass; and the .repared mass is then sub'ected to mol( ing I y pressure, which may be o the order of 5,00()

pounds to the square inch, for the pur ose of forming the'material'sinto substantially the finished shape, the formed shape being of sufficient cohesive strength to allow of completion of the cementing reaction without substantial distortion ofthe molded sha e or handling damage.l

' 'llhe cementitious binder employed may be any substance capable of participating in the preliminary molding operation as herein described, and of reacting with a suitable reagent to solidify or set in to a solid, cohesive structure of the desired properties; and which will not soften or decompose under heat. Numerous. materials possess these properties, for example plaster of Paris, magnesite (magnesium oxide),

magnesium oxychloride, and the crystalliz? Cross Reference duration is usually sufficient.

ing or h drating cements generally, such as Portlan cement and other hydraulic Icements', all of which react with waterfto fiber and, if desired, fine cop r, brass orother metallic wires. When t e cement is Portland cement or magnesium ox chloride, a mixture containing 40% o this cement, (of which a fifth art ma be plaster of Paris) and 60% of fi re, wit lor withi i out wire inclusions, is recommended for the generality of products.

For severe conditions, a mixture com rising 100 pounds of clean asbestos bre, opened and carded, from 12 to 25 pounds of short fine brass or copper wire, and -20 pounds of Portland cement, is found to be eminently satisfactory. filamentous inclusion mi situations in which wire is undesira le. The mixture of base material and cementitious bin'der so produced lmay now be formed to shape by pressure, for instance in. a metal mold suitable to the shape to be made. For

molding, the mixture may be dampened with its setting reagent, e. g., water, but the proportion of liquid shoul not exceed 20% by weight. The purpose is not to form a Allg' other strong ht e em loyed in wet plastic, but so to adjust the com onent proportions of the materials as to.ena le the mass to be molded by pressure. The mold, charged and ta'mped cold and dry, may, for example, be sprinkled with a suitable quantity only of water, and the charge then subjected to appropriate highpressure; application ofv`the molding moisture is recommended to be so iliade.

A pressure of two oi' three tons to the I "square inch -is advisable to insure a solid,

uniformly resistant mass adapted to withstand subsequent high pressure without damage. But it is not necessary `to prolong the application of pressure; several seconds Upon removal from the mold, the shaped article is hard, firm and strong,'and may be handled and- -stored without injury. Slight activation of the cement by -the ,moisture added may contribute to this result, but substantial or completev settin of` the cement has not been effected, and t e mass is predominantly a mechanical aggregate at this stage, which is sufiiciently strong -for removal from the mold and handling. In .the mass so formed the relatively 'dry'. cementitious material is uniformly dispersed throughout the molded shape, compacted into intimate physical contact with the fibrous and other inclusions, and substantially without voids of gross dimensions. The sub uent behavior of the material may be attributed in part to the presence throughout the material of voids of capillary size.

Subsequent treatment may, nhowever, be carried out in the mold, or a part of the mold; for example, the block 5 'of Fig. 2 and the shoe casting 6 need not be' se arated, the block 5 remaining attached to t e Walls of the cavity in the brake shoe.

To effect com letion and setting of the cementitious bind)er, the molded article may now be subjected to radual absorption of the reagent appropriate to completion of the cementitious element. If; as in the preferred case, the comminuted cement is an anhydrous form of the completed cement, this step may be carried out by exposure of the molded sha to an atmosphere heavily charged wit water-vapor during several days or weeks, this time depending upon the thickness of the molded shape and its capillary characteristics, but in an case for a sufficiently long period thoroug ly to supply to all of the interstices enough water in a vaporous or` nebulous state to solidify the cement. Exposure for three weeks in a "fog room, a chamber maintained at a temperature of about 38 to 43 C., in which the air is heavily laden with water-vapor, under conditions not conducive to precipitation of moisture upon the molded shapes (e. g., the sha es are kept at a temperature at least as hig as the air), is recommended. 4Upon removal` from -tlle fog room, the

. moldedshapes have attained a high solidity and strength.

The articles are now subjected to a suitably elevated temperature, for example,

from to `82 C., until substantially all excess of the cement-setting reagent above that required by the'setting reaction is vaporized and removed .from its internal structure. Thorough drying is important to successful completion of the manufacture. But this desiccation should not be carried -out to such a degree, nor at such a temperature,

as to dehydrate or decompose the solidified tegrated shaped bodies of pressure-resistant cement.

The fog-room treatment .mayl be so controlled as to provide approximately a suiiicient amount only of water-vapor to react with and set the cementI without any substantial excess, and in that case 'heatin for drying need not vhe prolonged beyon the time required for removal of superficial excess moisture.

The product may now be completed byA thorough impregnation with an oily material or composition, preferablyin accordance .with the method of the Letters Patent to William R. Seigle, Nos. 1,395,744, dated November 1,1921, and 1,436,362 dated No-l about l130 C.; and thereafter heating the articles, if desired in an inert atmosphere of carbon dioxide (CO2), above the temperature 'and during the time necessary to pol lymerize the oil by heat, and so change the homogeneous oily impregnant in the capillary spaces to a solid body; for example, heating to about 250 C. for 24 hours. But if the impregnant` has been subjected to preliminary catalytic hydrogenation, for' example, to a degree at which its iodine number has fallen to from 120 to 130,-polymerization by heat may be carried out by subjecting4 the impregnated shapes to a temperature ranging from 160 to 240 C. moreo'r less, for 24 hours, more or less, in ac- `cordance with the thickness of the article contact surface by machining or grinding,

but one of their more valuable characteristics is found in the relative accuracy of their retention of their molded form. This method of manufacture therefore produces a product having the industrial advantage 'of sufliciently reliable accuracy ofdimension for interchangeability, a prime consideration in the use principally demanding the product of this invention. For other characteristics the formed shapcs are of a material presenting a reliably uniform worn surface of the right quality of coefficient of friction, changeless under heating, and not absorbent of oils; and therefore peculiar] effective as a brakin surface in contact wit iron 'or steel brakerum or clutch members.

1. The method of making artiicially'inreacted upon thereafter to reach a' solidified i *I i -state while maintaining the said molded shape. y

v vwl UNG 0a PLASTIC ture in quantity 2. The method. of making artificially inl tegrated shaped bodies of pressure-resistant and friction-resistant material comprisin as steps, mixing in a dry state asbestos an a powdered cementitious substance ca able of solidification by reaction with a llquid reagent, applying to the materials a quantity of the reagent insufiicient to cause a. complete reaction, moldingr the relatively dry materials to shape under pressure, and thereafter subjecting the molded mass to 'a solidifying reaction.

3. .The method of making artificially integrated shaped bodies of pressure-resistant and friction-resistant material comprising as'steps, subjecting a mixture of a blbulous powdered ccmentitious material, a heat-resisting fibrous substance and moisture 1n quantlty insufiicient to cause the materlals to reach a fictile state, to molding pressure, and thereafter treating the molded Ashape to complete a solidifying reaction of the-cementitious material..

4. The method of making artificially .integrated sha ed bodies of pressure-resistant and friction-resistant material comprising as steps, subjecting a mixture of an anhydrous powdered cementitious material, a heat-resisting fibrous substance and molsture in quantity insufficient to cause the materials to reach a fictile state to molding pressure, and thereafter treating the molded shape by exposure to water vapor to complete solidifying reaction 'of' the cementitions material.

5. The method of making artificially integrated shaped bodies of pressure-resistant and friction-resistant material comprising as steps, subjecting a mixture of a bibnlous, powdered cementtious 1nater1al", a heat-resisting `fibrous substance and moisinsufiicient to cause the materials to reac a fictile state, to molding pressure sufficient to compact the mass` into a state having capillary voids only, and thereafter treating the molded shape to complete solidifyi'ng reaction of the cementitious material by slow absorption of a solidifying reagent.

6.- The method of making artificially integrated shaped bodies of pressure-resistant and friction-resistant materials comprising as steps, mixing in a dry state asbestos and a powdered cementitious substance ca able of solidification by reaction with a liquid reagent, applying to the materials a quantity of the reagent insufiicient to cause a complete reaction, molding the relatively dr materials to shape under pressure, and s ulijectin the molded mass to a solidifying reaction y prolonged exposure to vapors of the reagent.

7. 'I he method of making bodies comprising asbestos and a water-solidifying cement comprising mixing powdered cemen- MUSS HSTGTGHCB titious material and opened fibrous asbestos,

Examiner moistening the material with insufficient.

water to cause plasticity or solidification, subjecting the material to pressure, and subjectin the compressed mass thereafter to a moisture-laden atmosphere to cause solidification.

8. The method of making artificially integrated shaped bodies 4of pressure-resistant and friction-resistant materials comprising as steps, molding a mixture of fibrous heatresistant material and a comminuted bibulous cement, causin a solidifying reaction of the cement in t e molded shape, driving off any excess of the solidif ing rea ent by heat, and impregnating t e capil ary spaces of the molded shape with an oily substance capable of a hardening'reaction after impregnation.

9. The method ofmaking artificially integrated shaped bodies of pressure-resistant and friction-resistant materials comprising as steps; molding a mixture of fibrous heatresistant material and a comminuted bibulous cement, causing a solidi ingreaction of the cement in the molded s ape, driving ofl' any cxcess of the solidifyingreagent by heat, and impregnating the caplllary spaces of the molded sha e with an oil molecularly saturated in part y an introduced reagent, nd capable of hardening after impregnalon.

10. The method of making artificially integrated shaped bodies of pressure-resistant and friction-resistant materials comprising as steps, molding` a mixture of fibrous heatresistant material and a comminuted bibulous cement, causing a solidiying reaction of the cement in the molded s iape, driving ofl" any excess of the solidifying reagent by heat, and impregnating the capillary spaces of the molded shape with liquid tung oil, and subsequently causing solidification of the impregnant.

11. The method of making artificially integrated shaped bodies of pressure-resistant and friction-resistant materials comprising as steps, molding a mixture of fibrous heatresistant material and a comminuted bibulous cement, causing a solidifving reaction l -gate with less than sufiicient water to cause the cement to solidify; pressingthe aggregate into a mold at pressures of the order oflive thousand pounds to the square inch to V:form a coherent molded shape completving the solidification of the cement in the product; im-v molded product; drying the pregnating the dry product with a liqlui substance capable of solidification by mo ecular saturation, and solidifying the impreg- 13. An artificially integrated molded and sha d lbody for use asa friction'melnber, sai body comprising a heat resistant librouscomponent everywhere in its substance 1n intimate cohesive contact with a cementitious element. free combined water,

Lasa-me from an excess of un-4 and having'therein c a il- Vlary voids capable of substantially compete of said block being occu ied b a product of molecular saturation o an oi polymerizable by heat.

. Signed by me at Newr York city this 29th day of April, 1924.

, PHILIP 1A. ANDREWS.4

a moleculary-sat- 

